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Caledonia-5 & Caledonia Retailer Assembly Manual

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Caledonia-5 & Caledonia Retailer Assembly Manual CALEDONIA-5 & CALEDONIA RETAILER ASSEMBLY MANUAL TABLE OF CONTENTS LIST OF TOOLS & SUPPLIES Important Information .................. 1 Electric Wire Routing & Installation. 19 This manual outlines a number of procedures for making adjustments to the Caledonia-5 and Tools Tools List of Tools & Supplies. 2 Mechanical Cable Routing & Installation .........21 Caledonia bicycles. The following tools and Caledonia-5 & Caledonia Parts List. 3 Handlebar Routing - Electric. 23 parts listed are required for these adjustments. Bicycle workstand (types which secure bike by the seatpost, or Pedal wrench Small Parts ....................... 4 Handlebar Cable Routing - Mechanical. 24 Cervélo strongly recommends that all assembly and adjustment procedures be performed by an pro-type stand with fork mount) Caledonia-5 AB09 Handlebar ............... 7 Seatpost Assembly & Installation .............25 authorized Cervélo retailer. Caledonia-5 ST31 & ST32 Stems .............. 8 Di2 Battery Installation. 26 Torque wrench(es) with 2.5Nm to Brake rotor lockring tools Frame & Component Preparation .............. 9 Indexed Thru-Axle Installation ..............27 NOTE: All non-proprietary components 15Nm range and adaptors: such as those from Shimano or SRAM are Caledonia Fork Preparation & Installation ........12 Aero Thru-Axle Installation ...............29 available from your local distributor. Allen (Hex) head inserts: Caledonia-5 Fork Preparation & Installation .......14 Tire/Rim Clearance. 31 2mm, 2.5mm, 3mm, 4mm, 5mm, Hydraulic bleed kit Caledonia-5 Stack Adjustment. 16 Mudguard Installation ..................32 NOTE: This manual was developed 6mm, 8mm, 10mm to compliment the Cervélo General Brake Hose Routing. 17 User Manual, and is intended as Isopropyl alcohol a supplement to the assembly and Open ended wrenches: installation instructions supplied by 7mm, 8mm, 10mm, 17mm the component manufacturers (provided with this bicycle). Di2 wire tool – Shimano Cable cutters IMPORTANT INFORMATION Good quality bicycle grease & This manual is intended to assist Cervélo Retailers in the unique assembly requirements of NOTE: Cervélo strongly recommends that Pliers carbon assembly compound the Caledonia-5 and Caledonia bicycles. The assembly of this bicycle requires specialized all assembly and adjustment procedures be knowledge and specific tools. Failure to follow the supplied instructions and install only performed by an authorized Cervélo retailer. Saw cutting guide (Park Tool SG-7.2 Cervélo specified parts, my result in incorrect and unsafe assembly, resulting in loss of If you are a Cervélo Caledonia-5 or Phillips-head screwdriver or equivalent) control and serious injury to the rider. Caledonia consumer/purchaser reading this manual we suggest that before attempting to undertake any of the procedures in this This manual assumes that the retailer has the minimum required background and skill level manual that you consult your authorized Hacksaw (with carbon and required of all professional bicycle mechanics. See http://www.probma.org/ Slot-head screwdriver Cervélo retailer, or visit us at aluminum specific blades) www.cervelo.com/support 1 CER-CFA-V1 2020-01-15 2 CALEDONIA-5 & CALEDONIA PARTS LIST SMALL PARTS Designed to accommodate electronic, mechanical and hydraulic controls, the Caledonia -5 Item Description Cervélo Part No. Item Description Cervélo Part No. Item Description Cervélo Part No. and Caledonia frames are engineered to provide seamless integration of all shifting systems, regardless of method or brand. In order to do so, you may require the parts shown below: Down Tube Cable Stop BB Cable Guide/Cover BBG-0E0 ST32 Stem Spacer Kit SK-023 Assembly w/ Plug CBS-2DT112M2 Caledonia-5 Down Caledonia Down Caledonia-5 Down Caledonia-5 / Caledonia (Mechanical) Tube Port Rear Derailleur Tube Cable Guide Tube Di2 Junction A Down Tube Cable Stop DRH-WMN112 Rubber Plug for ST32 Blanking Plug Hanger w/Fixing Nut Dropout Electric Wire PL -338 Assembly w/ Plug Holder (Electric) Assembly w/ Plug (Mechanical) GR-DROPOUT-GUIDE Top Cap (Wireless) Guide (Electric) MT-294A CBS-2DT112M2 Threaded Fork Insert PL-350 QRI-THD CBG-DT-ASP w/Fixing Screw SP18 Seatpost w/ CL005 Fork Insert FKI-359 SP-SP18-ZERO Seat Tube Blanking Head 0mm GR-ST-CLOSED Plug(1x & Wireless) Accessory Mount Kit SP18 Seatpost w/ MT-LM-F-004 SP-SP18-25MM (Front) Seat Tube Di2 Wire Head 25mm GR-ST-GUIDE Grommet(Electronic) Seatpost Battery MT-BINT-SP2 Accessory Mount Kit Mount MT-LM-R-003 Brake Hose Guide CBG-DBH (Rear) Seatpost Clamp Cover SPCC-314 FDM Blanking Plate FDM-CVR Chainstay Guard PRO-CS-ASP Seat Tube Blanking Seat Tube Di2 Wire Plug(1x & Wireless) Grommet Seatpost Clamp BB Cable Brake Hose Guide Front Derailleur SPC-287A GR-ST-CLOSED GR-ST-GUIDE (Caledonia-5) Mudguard Mount Guide/Cover (Caledonia x3) Mount w/ Fixing FDM-0E0 MTA-302A Assembly Kit BBG-0E0 (Caledonia-5 x2) Screws Indexed Front Thru- QRA-LVR-F CBG-DBH Axle Down Tube Port PL -350 Dropout Cable Stop CBS-DRPOUT Blanking Plug Indexed Rear QRA-LVR-R Rear Derailleur Rear Derailleur Rear Derailleur Thru-Axle Press-In Cable Wire Guide Blanking Plug Down Tube Di2 Stop (Mechanical) (Electric) (Wireless) MT -294A Cervélo Front Aero Dropout Blanking Plug Junction A Holder QRA-AERO-F GR-DRPOUT-CLOSED CBS-DRPOUT GR-DRPOUT-GUIDE GR-DRPOUT-CLOSED Thru-Axle Wireless Down Tube Cable Cervélo Rear Aero Seatpost Clamp Guide Assembly w/ CBG-DT-ASP QRA-AERO-R SPC-SQ-R-2011-A Plug (Electric) Thru-Axle (Caledonia) 3 4 SMALL PARTS Rear Derailleur Accessory Mount Accessory Mount Kit Hanger w/Fixing Nut Kit (Rear) (Front) DRH-WMN112 Seatpost MT-LM-R-003 MT-LM-F-004 Frame Battery Mount Protector MT-BINT-SP2 Film Threaded Fork Seat Stay Seatpost Clamp Insert w/Fixing Mount Bridge Cover Screw Assembly SPCC-314 QRI-THD Mudguard Mount Assembly Kit MTA-302A Front Thru-Axle Threaded Fork Rear Derailleur See pages 11 and 25 for Mudguard Mount Insert with Hanger Mudguard Derailleur mounting instructions. Mount Blanking x2 Mudguard Mount Mount Front Derailleur Caledonia Plate (1x) Caledonia-5 Mount w/Fixing Seatpost Clamp FDM-CVR Seatpost Clamp Screws SPC-287A SPC-SQ-R-2011-A See page 11 for mounting instructions. See page 32 for mounting instructions. FDM-0E0 5 6 CALEDONIA-5 AB09 HANDLEBAR 80mm CALEDONIA-5 ST31 & ST32 STEMS Cervélo ST31 Stem (Carbon) Rubber Plug Only use the components specified in this manual for ST32 80mm ST-C031-80 for handlebar and stem assembly. Failure to use the Top Cap Preload 90mm ST-C031-90 specified parts and to follow the supplied assembly 128mm PL-338 Fixing 100mm ST-C031-100 instructions may result in a loss of control Screw 110mm ST-C031-110 380mm M6 x 25 while riding and serious injury. 120mm ST-C031-120 400mm 130mm ST-C031-130 420mm ST32 Stem 440mm Top Cap Cervélo ST32 Stem Cervélo AB09 (Aluminum) Handlebar ST31 and ST32 compatible 70mm ST-A032-70 Accessory Mount Kit (Front). 38cm HB-AB09-38 80mm ST-A032-80 See page 11 for assembly 40cm HB-AB09-40 90mm ST-A032-90 instructions. 42cm HB-AB09-42 100mm ST-A032-100 44cm HB-AB09-44 110mm ST-A032-110 120mm ST-A032-120 130mm ST-A032-130 Tighten fork ST31 stem steerer fixing can not be screws to 5Nm. flipped for additional stack. Brake hose, cable housing and Di2 E-Wire runs in channels on underside of Only use the components specified in this manual ST32 stem can handlebar. for handlebar and stem assembly. Failure to use Tighten stem be flipped for the specified parts and to follow the supplied faceplate fixing additional assembly instructions may result in a loss of screws to 6Nm. stack. control while riding and serious injury. 7 8 FRAME & COMPONENT PREPARATION Lightly grease Rear Derailleur Hanger Fixing Nut and install Rear Derailleur Hanger 1. Slide the Seatpost Clamp Cover (SPCC- (DRH-WMN112) finger tight. Final tightening 314) onto the seatpost. Hold the frame using a secured seatpost only. will be done after rear wheel installation Clamping the top tube can damage the frame 2. Apply carbon paste to the frame and (page 28). If installing mudguards refer also and void your warranty. seatpost to be inserted into the frame. to page 32. 3. Insert the seatpost and the Seatpost Clamp (SPC-287A) into the frame Do not final tighten rear derailleur hanger assembly without rear wheel 4. Adjust height and torque the Seatpost installed. Doing so will result in a Clamp to 8Nm maximum. misaligned derailleur and poor shifting. Apply grease to the interior 5. Slide down the Seat Clamp Cover to fit sliding surfaces over the Seatpost Clamp. of the Seatpost Clamp wedge. If trimming is required, final 1. Lightly grease supplied M4 fixing screw. Install length should allow for a the Threaded Fork Insert (QRI-THD) and fixing screw, tightening only lightly. If installing Note: For Caledonia minimum of 70mm of seatpost seatpost installation: remaining in the frame, or the mudguards please refer also to page 32. minimum insertion dimension 2. Without wheel in place, install the axle and 1. Apply carbon paste to indicated on the seatpost, tighten until the flange meets the fork dropout the frame and seatpost whichever is greater. Failure to be inserted into the face, but does not compress the fork blades. to meet this requirement, may frame. result in damage to the frame not 3. Tighten the fixing screw to 3Nm. 2. Insert the seatpost into covered by warranty policy, or the frame. serious injury to rider. 4. Remove the axle and install wheel. Reinstall axle Secure the Front Derailleur With 1x chainring and tighten to 12-15Nm. 3. Adjust height and torque Mount (FDM-0E0) into frame setups, use the the Seatpost Clamp (SPC- with two fixing screws. Tighten Blanking Plate 5. Remove axle and wheel, and re-torque the fixing SQ-R-2011-A) to 6Nm to 3Nm. (FDM-CVR). screw to 3Nm. maximum. 9 10 FRAME & COMPONENT PREPARATION CALEDONIA FORK PREPARATION & INSTALLATION Ensure the Chainstay To install Accessory Mount (Front), 1.
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